solar system wire sizing calculator

http://solarpanelsvenue.com/calculator/wire-sizing-calculator/wire-sizing-calculator.htm

source: http://solarpanelsvenue.com/

comparision of solar,PVC and XLPE Cables

PV Trackers

Four main types of trackers

1.Horizontal singe Axis Tracker HSAT
2.Tilted single axis tracker
3.Azimuth Tracker
4.Dual axix tracker

Mounting Structures Manuacturers list

sl.no	Name of the company	Address
1	Lotus Industries	Plot no. 268, Panchasheela colony, Gandhinagar, Hyderabad, IDA, Balanagar, Hyderabad, Telangana 500037,Phone:093948 26067
2	VIMFAB	Plot No. 11, Phase- 4, Behind Topaz, IDA, Miyapur, Medak Rd, Rajiv Gandhi Nagar,Jeedimetla, Hyderabad, Telangana 500055,Phone:087900 73284
3	Nuevosol Energy Pvt Ltd	Nuevosol Energy Private Limited,Plot # 409, Road No. 81,Phase 3, Jubilee Hills, Hyderabad – 500 033,Telangana, India
4	pennarindia	3rd Floor, DHFLVC Silicon Towers,Kondapur, Hyderabad - 500 084, Telangana, India.Phone: 040-40061621 /22 /23/24.Fax: 040-40061618.E-mail: contact@pennarindia.com /pilhyd@bsnl.in
5	Suyash Metatech Pvt. Ltd	E-63, MIDC, Satpur, Nashik - 422 007. Maharashtra, India, Tel. No.: + 91 - 253 - 6604599, + 91 - 253 - 6563599
6	subhadraindustries	53/1, Kottige Palya, Magadi Main Road, Opp : Unani Medicle College, Hospital., Bangalore, Karnataka, India - 560091
7	krvfabrications	S. N. Balaji (Proprietor),No. 14, SIDCO Industrial Estate, Ambattur ,Chennai - 600098, Tamil Nadu, India.Call Us:  08376806850
8	Green Field Solar Solution Pvt. Ltd	Avinas Rajendran (Director) New No. 29, First Main Road, Shenoy, Nagar East  Chennai - 600030, Tamil Nadu, India.MOB-09643204288
9	Shree Umiya Sheet Metal	Manoj Shekhat (Managing Director) Shed No. 12/A, Rudrax,Complex-II, Near Trikampura Cross Road, Opposite Annapurna , Rest, G. I. D. C. Vatva, Phase III ,Ahmedabad - 382445, Gujarat, India
10	essofabtech	14, Kanjibhai Estate, Nr Bharat Gas Godown, Vinjol Patia,Mehmedabad Road, Vatva, Ahmadabad – 382445.,P: (079) 25841014 / 40041014
11	V N Roofing & Cladding pvt. ltd	V. N. Roofing & Cladding Pvt. Ltd. Naresh Agrawal (Director),Lata Tiwari,  C-14, MIDC, Kalmeshwar  Nagpur - 441501,Maharashtra, India
12	epackpolymers	61 – B & C, Udyog Vihar, Surajpur, Kasna Road, Greater Noida,U.P.) India. Pin – 201306,+91-9818666068, +91-8130444466
13	Aacess Tough Doors Private Limited	Ravi Chandra (Director Marketing)Plot No. B 8 & 9/1, IDA,Kukatpally, Gandhi Nagar,Hyderabad - 500037, Telangana, India
14	jindalsteelandpowerltd	Mohit Srivastava (Deputy Manager)Ist Floor, Tower B, Jindal Centre,Plot-02, Sector-32 Gurgaon - 122001, Haryana, India
15	Mitaso Comtel Limited	Address: Plot No-119-120, Sector 6, Sector 6, Faridabad, Haryana,121006 Phone:0129 408 5064
16	DPW Solar Electric	Albuquerque, NM, United States,Phone:+1 505-889-3585
17	schletter	51B/32 Vrindavan Society •  Majiwade •  Thane (West) ,   Pin- 400601,Tel.: +91 9167 595798   info@schletter.in
18	Professional Solar Products	1551 South Rose Avenue, Oxnard, CA 93033, United States,Phone:+1 805-383-7171
19	Quick Mount PV	2700 Mitchell Dr, Walnut Creek, CA 94598, United States
20	IronRidge	Hayward, CA, United States Phone:+1 800-227-9523
21	Unirac	1411 Broadway Boulevard NE Albuquerque NM 87102-1545 USA,Telephone: 505-242-6411
22	Snapnrack	contact@snapnrack.com,877·732·2860775 Fiero Lane Suite 200,San Luis Obispo, CA 93401
23	Renusol GmbH	Piccoloministraße 2, 51063 Köln, GermanyPhone:+49 221 7887070
24	Up Solar America	600 Montgomery St, San Francisco, CA 94111, United States,Phone:+1 415-263-9920
25	Orion Solar Racking	7012-, 7098 Elm St, Commerce, CA 90040, United States, Phone:+1 310-409-4616
26	prosolar	Professional Solar Products,1551 S Rose Ave Oxnard, CA 93033,contact@prosolar.com
27	solarflexrack	U.S. and International Inquiries:info@solarflexrack.com, Phone: 888.380.8138
28	TOUGH TRAC	NewYork,sales@toughtrac.com
29	hillsmithsolar	UK,  sales@hillsmithsolar.com
30	Chiko Solar	NO.878 Cheng Liu Rd.Jiading District Shanghai ,China,sales@chikolar.com
31	Roller Die	Roller Die + Forming 1172 Industrial Blvd . Louisville , KY 40219,Phone: 502-804-5571
32	Grace Solar	ADD：NO.E,Gaoqi Industrial Park,Huli District, Xiamen, Fujian, China.TEL：0086-592-5239037,Email：info@gracesolar.com
33	Xiamen Sunforson Power Co.,Ltd	Unit 817,An Ling Road No. 993,Hu Li District,Xiamen China.Tel:   86-592-3655325,86-592-5735570,Fax: 86-592-5115756,E-mail:info@sunforson.com
34	patriotsolargroup	1007 Industrial Avenue,Albion, MI, USA 49224,517.629.9292
35	K2 Systems	Unit 46 Easter Park,Benyon Road,Aldermaston, Berkshire RG 7 2PQ, United Kingdom,Tel. +44 (0) 1189 701280

Solar Cable Maufacturers

S.No	Company	Address	phone	email
1	Eland Cables	Highgate Studios, 53-79 Highgate Rd, London NW5 1TL, United Kingdom	+44 20 7241 8787	sales@elandcables.com
2	QC Solar cables	No.31 Xinfa Road, SIP, Suzhou, Jiangsu, China		market@quick-contact.com  (sales)
3	Thermocables	No 28, Nagarjuna Hills, Punjagutta, Punjagutta, Hyderabad, Telangana 500082	040 2309 0040	info@thermocables.com
4	Radox solar	Skyline place Frenchs Forest Sydney Australia	+61 2 8977 1200	radoxaustralia@hubersuhner.com
5	Centurion solar cables	F-1775, DSIIDC Indl. Estate, Narela, Delhi - 110040, India		info@centurioncables.org
6	olex-nexans	1300 CABLES ,Australia,Business Phone: 1300 222 537 E-mail address: olex.customerservice@nexans.com	+ 61 3 9281 4444	olexmktmgr.photovoltaic@nexans.com
7	TECHSUN-prysmian group	Italy		marketing.energy@prysmiangroup.com
8	amson solar cables()	Uttarpradesh	-4542080	amson@amon.info
9	APAR Industries ltd	907,9th Floor, BabuKhan Estates, Basheer Bagh, Hyderabad, Telangana 500001	040 2329 8514	apar.hyderabad@apar.com
10	Betaflam solar cables	switzerland	+41 (0)62-288-8282	infrastructure-datacom@leoni.com
11	Axiom Solar pvt ltd	Kushaiguda,Hyderabad	+91-99590 55156	suresh@axiomsolar.com
12	Tamradhatu	205/212, Iind Floor, 32, Ezra Street, Kolkata, West Bengal 700001	033 2221 8583	enquiry@tamradhatu.com
13	Advance cable	G-1,Sunrise Serenity,No.1,M.R.Garden,Gedallahalli,Aswanthnagar,Bangalore-560094.India	91-80-23516733/34	sales@advancecable.in
14	Havells solar cables	QRG Towers,Noida	91- 120- 3331000	marketing@havells.com
15	Hanferd Cables	Plot No-14/1A, Site IV, Industrial Area, Sahibabad,Uttar Pradesh -201010,India	91 0120 2775892	info@hanferd.com
16	Supreme cables	No:159,Linghi Chetty St,Parrys,Chennai-600001	9841060801	supreme_ec@rediffmail.com
17	Relema cables	Plot No. 92, Sec.56,Phase IV,Kundli Industrial Area HSIIDC, Sonipat, Haryana-131028 (INDIA)	91-130-6549900	info@relemacindia.com
18	Amersol-nexans	350 Bailey Road,El Dorado, Arkansas 71730,USA	800-643-1516
19	Spectrum cables	Tech Nr Amber Gum Industries, Nr Maria Park, Canal Road, Opp Hotel Cozy, Narol, Ahmedabad- 382 405, Gujarat India	9824011251	spectrumcabletech@gmail.com
20	XLPE Cables	No. 234, 3rd Floor, Garudachar Complex, Chickpet, Bangalore, Karnataka, India - 560053	91-9341285508	kflexcables@gmail.com
21	Belden solar cables	Belden - India ,Unit 503, Wellington-II , Wellington Business Park, Off Andheri ,Kurla Road, Opp. Skyline Ikon ,Mumbai , Maharashtra 400059 ,India
22	Erico Solar power Solutions
23	Shilpi cables	A-19/B-1 Extension,Mohan Co-op. Industrial Estate,Mathura Road, P.O. Badarpur ,New Delhi - 110044, India	91 11 43117900	info@shilpicabletech.com
24	Polycab	208-209, 2nd Floor Bhuvana Towers S D Road, Secunderabad, Telangana 500003	040 6632 6228	info@polycab.com,
25	southwire
26	https://www.civicsolar.com
27	http://www.siechem.com/
28	http://www.finolex.com/
29	http://cablecorporation.com/
30	http://www.unistar.co.in/
31	http://www.bhuwalcable.com/

Tips To Buy Solar Cable

Solar Cables are used as an interconnection cable in photovoltaic power generation. Solar panels and other components of the photovoltaic system are interconnected using Solar Cables. The Solar Cables are UV resistant and can bear harsh weather conditions. Solar Cables are mostly laid outdoors and they have the capacity to function properly in extreme temperatures.

Nowadays, many factories and offices have their own photovoltaic systems, on which the power supply needs of the whole factory or office relies. A  small error in any part of this system, even in the Solar Cables, may shut down the supply in the whole system and can result in tremendous loss. Therefore, selecting a properly functioning Solar Cable is an important aspect that needs to be considered. Following are few tips that you must consider while selecting Solar Cables:

• Solar Cables that you select must be of high-grade material. Solar Cables made from low quality material may not function as efficiently as the ones made with high-grade material.
• The material used for making Solar Cables must be sunlight-resistant, corrosion-resistant and must be protected against agents like water and dust.
• The Solar Cables that you are selecting should also be resistant from flame, oil, UV and ozone.
• The Solar Cables should also be free from halogen and should be flame retardant so as to prevent fire.
• The Solar Cables that you select for installation must comply with EC Low-Voltage Directives.
• The material that is used for making Solar Cables must be flexible enough to facilitate easy installation.

HOW TO USE MC4 CONNECTORS AND EXTENSION CABLES

What is an MC4 connector and an MC4 extension cable? If you're asking this question, you've probably noticed that most modern high power solar modules are manufactured with wire leads that have MC4 connectors on the ends. Years ago, solar modules were built with a junction box on the back that required the installer to manually attach wires to the positive and negative terminal posts. This method is still used, but it's slowly becoming a thing of the past. Modern solar modules tend to use the MC4 connectors because they make wiring your solar array much simpler and faster. The connectors come in both male and female types which are designed to snap together. They meet the requirements of the National Electric Code, they're UL certified and the preferred connection method of electrical inspectors. Due to the locking mechanism of the MC4 connectors, they will not come unplugged and are well suited for outdoor environments. The connectors can be separated but it requires a special MC4 unlocking tool.


Wiring MC4 Equipped Modules in Series:

If you have two or more solar modules to wire in series, the MC4 connectors make it very simple. Take a look at the first module and you'll notice that it has two wires extending from the junction box. One wire is the DC positive (+) and the other is the DC negative (-). Generally, the male MC4 connector is associated with the positive lead and the female connector is associated with the negative lead. This may not always be the case, so it's always a good idea to look at the markings on the junction box or test the polarity with a digital volt meter. A series connection is when you wire the modules together by connecting the positive lead on one module to the negative lead on another module. The male connector will snap directly into the female connector. Here's a simple diagram illustrating this.

As you can see, the two modules are now connected together by the two leads. This increases the voltage of the circuit. For example, if your modules are rated for 18 volts at maximum power (Vmp), then two of them connected in series will measure 36 Vmp. If you connected three modules in series, the total Vmp would be 54 volts. The current at max power (Imp) will be constant when wiring a series circuit.

Wiring MC4 Equipped Modules in Parallel: 

Parallel wiring requires the positive leads to be connected together and the negative leads to be connected together. This method will increase the current at max power (Imp) while keeping the voltage constant. For example, let's say your modules are rated for 8 amps Imp, and 18 volts Vmp. If you connect two of them in parallel, your total amps would be 16 amps Imp and the voltage would remain at 18 volts Vmp. When wiring two or more modules in parallel, you will need some additional equipment. If you're only using two modules, the easiest method is to use MC4 multibranch connectors. You obviously can't connect two male connectors or two female connectors together, so we use the multibranch connectors to accomplish that. There are two different multibranch connectors. One type accepts two male MC4 connectors on the input side and has a male MC4 connector for its output. The other type accepts two female MC4 connectors and has a female MC4 connector for its output. Essentially, you've stepped down the number of wires from two positive and two negative to one positive and one negative. Here's a diagram so that you can see what it's doing.

If you are paralleling more than two modules or you're paralleling strings of modules, that requires a device called a PV combiner box. You no longer need the multibranch connectors because the combiner box will be performing the same function. The multibranch connectors are only suitable for paralleling two modules together. If you need to connect more than two modules or strings in parallel, a combiner box is used. The total number of modules that can be combined will depend upon the electrical rating and physical size of the combiner box. Whether you've combined your modules with the multibranch connectors or with a combiner box, you'll need to understand how to select and use MC4 extension cables.

What is an MC4 Extension Cable and How do I use Them?

Don't feel bad if you're confused by the MC4 extension cables. If you've never worked with solar modules before, they can be a little intimidating. First of all, they're expensive. Nobody wants to purchase an expensive cable and later find out the length is too short after its been cut. Cut cables cannot be returned, so we want to be sure you fully understand how to choose the appropriate length and how to use them to connect your panels together.

An MC4 extension cable is very similar in concept to an electrical extension cord. Just like an extension cord has a male plug on one end and a female plug on the other, an MC4 extension cable has a male connector on one end and a female connector on the opposite end. They are available in many different lengths from 8 feet to 100 feet long. Lets go back to our first example of wiring two modules in series. Once you've got the two modules connected in series, you need to use MC4 cables to bring that power to wherever your electrical equipment is located (usually a circuit breaker and a solar charge controller). Systems using two modules are generally used for RV's and boats, so you can usually use the extension cables along the entire distance. When you use solar panels on a house or cabin, the distance that the wire must travel is normally so long that using an extension cable is no longer practical. In those situations, the extension cables are used to connect the panels to a combiner box. That way you can use less expensive wiring (such as THHN rated insulation) inside electrical conduit to cover greater distances at substantially less cost than the MC4 cables. Let's say that the total length of wire needed to go from the two modules to your electrical equipment is 20 feet. Note: This is where most people start getting confused. You only need one extender cable. We offer an extender cable in a 50 foot length, which is best suited for this situation. Remember that the two solar modules that you've already connected together have one positive lead with a male MC4 connector and one female lead with a female MC4 connector. To travel the 20 foot distance to your equipment, you will need a 20 foot wire with a male connector and a 20 foot wire with a female connector. This is achieved by cutting the 50 foot extension cable in half. That will give you a 25 foot wire with a male connector and a 25 foot wire with a female connector. That allows you to plug into both leads of your solar panel and it gives you plenty of wire to get to your destination. Sometimes cutting the cable in half is not always the best solution. Depending upon the location of the combiner box, there may be a greater distance from one side of the panel string to the combiner box than from the opposite side of the panel string. In this case, you will want to cut the extender cable at a spot that allows both cut ends to reach the combiner box with a little slack to work with. This diagram shows you an example of that scenario:

For systems using a combiner box, you simply choose a length that, when cut, is long enough to be terminated into the box. You can then strip back the insulation from the cut ends and terminate them to a bus bar or circuit breakers.

Disconnecting MC4 Connectors:

This is an MC4 disconnect tool. If for some reason you need to disconnect your MC4 cables, you will need one of these. You must insert the two extended posts on the end of the tool into the side of the female MC4 connector. This disengages the locking mechanism on the male connector and allows the two connectors to separate. The disconnect tool is sold as a set of two. Two tools are required if you ever need to disassemble the connectors. This is almost never necessary. Generally, one tool is all you will need.

MC4 Connector Specifications:

Manufacturer: Multi-Contact USA

Rated for 30 amps max (the connector itself, not the wire)

Rated for 1,000 volts max

Rated temperature range: -40 degrees C to +90 degrees C (-40 F to 194 F)

Note: Do not cut the MC4 connectors off of your solar modules. That voids the warranty of most manufacturers.

Source:http://www.solar-electric.com/how-to-use-mc4-connectors-cables.html/

TÜV INTERCERT Certifications

• IEC 62108: for CPV Modules -Design qualification and type approval
• IEC 61215: Crystalline silicium terrestrial photovoltaic modules – Design qualification and type approval
• IEC 61646: Thin-film terrestrial photovoltaic modules – Design qualification and type approval
• IEC 61730: Photovoltaic module safety qualificationIEC 61730 Photovoltaic (PV) module safety qualification
• IEC 61701: Salt mist corrosion testing of photovoltaic modules
• IEC 62716: Ammonia corrosion testing of photovoltaic modules
• IEC 60068-2 - 68 and LC2: Desert Dust Tests of Solar Modules
• IEC 62759-1: Transportation testing of photovoltaic modules
• IEC 60904-9: On-site performance characterization of solar simulators
• PID (Potential Induced Degradation) testing and rating for PV modules
• EL (Electroluminescence) testing for PV modules
• Made in EU certification
• System pass photovoltaic
• Manufacturing TÜV INTERCERT PV Rating

ABBREVATIONS

SL NO	Abbrevation	Fullform
1	GTI	Grid Tied Inverter
2	SHS	Solar Home System
3	EPBT	Energy pay back time
4	EROI	Energy Return on Investment
5	4M	Man Material Machine Money
6	5M	Man Material Machine Money Method
7	ETDC	Electronics Test and Development center
8	SCADA	Supervisory Control and Data Acquisition
9	PLC	Programmable logic controller
10	JNNSM	Jawaharlal nehru National solar mission
11	NABARD	National bankk for agriculture and Rural development
12	BOS	Balance of System
13	FIT	Feed in Tariff
14	ESD	Electro static Discharge
15	EPA	ESD Protected area
16	GBI	Generation Based Incentive
17	AJB	Array Junction Box
18	CSP	Concentrated Solar Power
19	CST	Concentrated solar Thermal
20	PCU	Power Conditioning Unit

Solar Cables

SOLAR CABLE

Solar cable is the interconnection cable used in photovoltaic power generation. A solar cable interconnects solar panels and other electrical components of a photovoltaic system. Solar cables are designed to be UV resistant and weather resistant. It can be used within a large temperature range and are generally laid outside.

Special Properties of Solar Cables

1. Lifetime reliability: lasts up to 30 years even under tough external conditions.
2. Outdoor durability: resists extreme temperatures (-40°C to 120°C maximum at the core) and ozone resistant.
3. UV resistance: full protection against ultraviolet rays.
4. Halogen-free: Low Smoke Emission & Low Toxicity/Corrosivity during fire.
5. Properties against fire: flame retardant, fire retardant.
6. Flexibility and stripability: for fast and easy installation.
7. Fully recyclable: in accordance with new environmental regulations.
8. Easy installation with color identification (blue, red).
9. Suitable to common connector types.
10. UL, TÜV, UTE and IMQ-certified.

Required Features of Solar cable

Chemical Features

1. Weather resistant
2. Resistant to mineral oils
3. Resistant to acids & alkaline

Thermal Features

1. Maximum conductor temperature of operation-120° C during 20000 hours
2. Minimum operating temperature: - 40° C

TUV Certification

Electrical Features

1. Voltage rating :1.5 (1.8) KV DC / 0.6/1.0 (1.2) KV AC
2. High voltage test: 6.5 KV DC for 5 minutes.
4. Rated Voltage: 0.6/1 kV AC .
5. Rated DC Voltage: 1.5 kV.
6. Maximum Permitted DC Voltage: 1.8 kV (conductor / conductor, non earthed system, circuit not under load).
7. Maximum Permitted AC Voltage: 0.7/1.2 kV .
8. Working Voltage: DC 1000 V.
9. Insulation Resistance: 1000 MW-km.
10. Spark Test: 6000 Vac (8400 Vdc).
11. Voltage Withstand: 6500 V as per EN50395 for 5 min.

Mechanical Features

1. Resistant to Impact , tear & abrasion
2. Minimum bending radius – 4 times of overall diameter.
3. Safe pulling force -50 N/sqmm.

Source:

The solar cable is called the other kind of outdoor cable, which distinguishes itself from the ordinary one. With the rapid development of the photovoltaic power generation industries, the solar panel cable is used more and more intensively. According to statistics, the solar cable used in Europe is as long as 60 thousand kilometers and in North America the length is up to 35 thousand kilometers by the year of 2010.

The solar cable is mainly used in an outdoor environment. Also it can be used to connect the photovoltaic system outside the building to the electric equipments inside. Viewed from the demands of the environmental conditions, the solar panelcable fuses 3 kinds of properties as follows, which shows the particularity of the solar panel cable.

The first one is the requirement of the flame retardancy for the cables. Normally it only makes demands on the house cable. The insulation of the solar cable is made up of the polyolefin which has a feature of flammability. It can effectively block the flame dispersion. At present the standard one used widely is not very strict with the demand of flame resistance, but in the future more stringent test condition will be adopted.

Then the solar cable has good performance on the UV resistance which the outdoor cable should have. Compared to the insulation, the sheath of the cable has more contribution. The insulation and the sheath are structurally independent. Even the sheath crazes the crack will not spread to the insulation. There is UV stabilizer in the sheath which effectively prevents the embrittlement and cracking problems under ultraviolet radiation. Now most of the sheath is black on the market. The solar branch that can provide the sheath of other colors is few because of the special UV stabilizer it needs.

Thirdly the solar cable should reduce the influence of the thermo-oxidative ageing which mainly determines the working life. Both the outdoor and indoor cables suffer from the ageing problem. However, the polyolefin which is the primary material of the insulation and sheath has enough capability to solve the problem. As time goes by, the performance of the solar cable will not change too much.

In addition to these, the working life of the solar panel cable is required to be not less than 25 years even in terrible conditions which the usual cables can hardly meet. It shows how complicated the solar cable is. Through all these stringent requirements of the solar cable, we can see why we call it the other kind of outdoor cable or the amazing cable.

In the future development we will demand a higher level of the solar cable and it will be used more frequently in our daily life.

datasheets
http://nordicindia.com/wp-content/uploads/2015/02/Solar-Cable-Data-Sheet5.pdf

Connectors

MC4 connectors are used to connect multiple solar panels or groups of solar panels together in a solar field, and typically used in parallel applications. The metal pin is made from high quality machined copper and sealed tip that can ensure excellent electrical contact.

Technical data:
Insulation material:PPO
Rated current:30A
Rated voltage:1000V
Test voltage:6KV(50Hz,1Min)
Contact material: copper, tin plated
Contact resistance:5m?
Degree of protection:IP67
Safety class:II
Flame calss:UL94-V0
Insertion force: ?50N
Withdrawal force: ?50N
Ambient temperature range:-40 C ~ +90 C
Suitable cable:2.5~6.0mm2AWG14/12/10
Pin dimensions: ?4.0mm2 &6mm2

MC4T connectors are used with MC4 connectors to connect multiple solar panels or groups of solar panels together in a solar field, and typically used in parallel applications. The metal pin is made from high quality machined copper and sealed tip that can ensure excellent electrical contact. 

Specifications 

Insulation material: PPO 

Rated current: 50A 

Rated voltage: 1000V 

Test voltage:6KV(50Hz,1Min) 

Contact material:Copper,Tin plated 

Contact resistance:5mΩ 

Protection degree: IP67 

Safety class: Ⅱ 

Flame class:UL94-V0 

Insertion force: ≤50N 

Withdrawal force: ≥50N 

Ambient temperature range:-40℃~+90℃ 

Pin dimensions: φ4.0mm 

Suitable cable: 2.5~6.0mm2 AWG14/12/10

Other Module Locations

1.Vetical wall

2.Open Ground

3.Vehicle Top

4.Water Mounted

5.Canopy Type

Mounting Structures

The mounting structure is the supporting structure that holds the solar panels or arrays of solar panels to the ground.


Mounting structures support solar panels on the ground, or on the rooftops.

Solar panels work best when they recieve as many hours of sunlight as possible and are mounted at an optimal tilt and facing the south. There are several ways to mount solar panels to maximize solar exposure and energy production.

1. Panels need to be attached to the roof or to the ground. The panels themselves cannot be directly attached to the ground owing to their structure, and hence they need a separate mounting structure.
2. Solar panels need a secure fastening to the roof or ground to protect against winds. Mounting structures do this function. 
3. Solar panels also require protection against water and other elements that gather on the ground or on the roof.
4.  In case of rooftop solar, the roof might not have a suitable inclination to get the maximum from sunlight. Having mounting structures at a suitable angle can tilt the solar panels at an optimal angle. 
5. You need some space between the solar panels and the ground for the cables etc. In addition, you need space for repairs and maintenance of the panels.

What are the mounting structures made of?
Mounting structures are usually made of steel, which is galvanised for protection against corrosion. Lightweight structures could also be made from Aluminium.

Do the mounting structures require maintenance?
Typically, mounting structures require little or no maintenance, unless these structures come along with solar trackers.


How much do mounting structures weigh?


There is a wide variety of mounting structures available, and hence it will be difficult to put down a specific number. However, in general, one can expect really lightweight mounting structures from Aluminium to weigh as low as 25 Kg /kW to sophisticated stainless steel structures that could weigh as high as 200 Kg/kW. The mounting structure area surely is an evolving field and one can expect many improvisations in design and materials in the coming years.

Are there lightweight mounting structures?

Yes. A number of companies offer lightweight mounting structures made of Aluminium, though it is not entirely clear which of the two structures – Aluminium or Steel – is better. It is quite possible that lightweight mounting structures are more suitable for specific types of roofs or land that might not require the durability of steel structures.

How much do mounting structures cost?
Typically, mounting structures cost about 10% of total system cost for large solar power plants and about 15% for smaller power plants.

What are solar mounting structures?

Mounting systems can often be the most complicated portion of a solar PV system installation as they form the foundation of the system – they protect the modules, the roof and people over a lifetime that can exceed 25 years. Thus, it can be seen that solar mounting structures are far more critical to the performance of solar power plants than most people think.

Why are they critical?
Solar panels perform at their best when they face perpendicular to the sun’s rays. But the sun’s position with respect to the solar panel changes throughout the day and over the seasons.
There are times when the direction of your roof may not be facing the optimal direction for maximum production. In such as scenario, rooftop mounting systems are utilized to position the panels in the required direction.

What benefits do they offer?

1. Maximizes energy production They orient the panels to receive maximum solar energy possible. Appropriate layout of arrays becomes very important for optimized cable length as well as optimized energy production. 
2. Enhances stability of the module They provide stability to the module/panel and hold them stable in the areas of strong winds. 
3. Fortification Rooftop mounted solar panels protect your roof from adverse weather conditions and, wear and tear. This, in turn, increases the lifetime value of your roof and structure.

A guide to mounting racks for solar panels (PV)

Speaking about solar PV systems most people usually refer at first to solar panels, secondly to inverters and batteries, thirdly to charge controllers.

But what about the structures you need to mount your system on a roof or a tracking systems? The correct and proper choice of the mounting racks (also called: mounting structures) for your solar system project is very essential in terms of the overall production, efficiency and lifetime of your solar panels.

Since it is a costly investment, the choice of mounting racks should not be disregarded as a minor consideration if purchasing solar systems or mounting solar modules.

Solar modules need to be secured, mounted and tightened on a very stable and durable structure, protecting the array against impacts from snow, wind, hail, rain and even minor earthquakes.

They are either mounted on ground, on roofs or on poles. In the solar market there are five basic types of mounting structures of which four a fixed-angle types (a-d) and one variable-angle type (e):

a) roof mounted racks

b) ground mounted racks

c) top-of-pole mounted racks

d) side-of-pole mounted racks

e) tracking system mounted racks


Roof mounted racks typically keep the wire run distances between the solar array and the battery bank or inverter to a minimum, but require roof penetrations and run danger of causing roof leakages, thus the roof must be well sealed.

Another disadvantage of roof mounted structures can come up if the roof orientation and angle is not optimal, thus wasting lots of potential energy that your system could generate.

For optimal system efficiency using a roof mounted structure you need to ensure that there is no shadow from trees or other buildings in the optimally free airflow path of your solar panels.

Moreover, according to 690-5 of the US National Electrical Code-NEC they require expensive ground fault protection (GFP).

Ground mounted racks do not require GFP, but need a precise foundation setup. Ground mounted structures run danger of being exposed to vandalism, accumulation of dirt, leaves and snow at the bottom of the array.

Therefore, ground-mounted racks are only recommended for secure locations preferably in clean and stable environments (with few snow or dirt on-ground).

Top-of-pole mounted racks are structures where mounting poles are secured into the ground and tightened with concrete and the solar module is mounted on the top of the poles.

The advantage is that it is rather not exposed to vandalism and accumulation of dirt, leaves and snow, but are not easy to clean.



Side-of-pole mounted racks are normally used for solar systems that comprise a small number of modules. They are particularly used for remote lighting systems that already come with a pole where they can be easily attached to.

Tracking system mounted racks can be used for all kinds of solar tracking systems as well as solar water pumping systems, allowing for a maximum of sun radiation that can be used for generating electricity.

They especially pay-off in hot climates. There are two different types of mounted structures for tracking systems, that are one-axis and two-axis.

The one-axis trackers are designed to track the sun movement from the east to the west while the two-axis systems track the sun's daily and seasonal course and are overwhelmingly used with PV concentrator systems.



Mounting rack material
Mounting racks can be made of different kinds of materials. Do not forget to ask your manufacturer about the material of his mounting structures in order to avoid wrong and post-project expensive choices.

The majority of manufacturers of mounting racks use Aluminum. It is not only low weight - thus decreasing weight pressure on the roof, pole or tracking system - but also corrosion-resistive, strong and compatible to the solar module frames of many manufacturers that are mostly made of Aluminum.

Another choice can be mounting structures made of stainless steel. Although stainless steel racks are very strong and resistant against environmental impacts such as hail, snow, rain etc. and can last for ages, they are nevertheless an expensive investment.

Wood-made mounting racks are cheap and easy to work, but are weak in consistence and bound to fail quickly particularly in wet environments.

Plastics-made mounting racks are also cheap, but not the optimal choice in terms of statics and lifetime. Like wood-made mounting racks , they may burn or even break if pressure on the solar panel (e.g. snow) is too high.

Last but not least, iron-made mounting racks are also easy to work and slightly more expensive than wooden racks , but quickly fall victim to corrosion and are not recommendable in wet environments.

Conclusion
If you purchase mounting structure you can usually choose from a wide range of manufacturers and a bunch of standard mounting structures.

Since every solar project and location requirement is different, it would be optimal to purchase a customized mounting rack, but they are expensive as compared to the standard solutions.

Thus it is advisable to do detailed calculation in terms of the mounting racks, taking into account the project site, sun radiation and mounting material that is proper for the project site and do efficiency/ pricing comparisons.

Sometimes, purchasing a customized solution may - despite possible efficiency losses with standard structures - may not be worth the investment.

If buying a customized solar system, optimally a complete one if you are an end-user that includes panels, inverters, batteries, charge controller and mounting rack, good and serious companies will provide you with a system design that in view of your individual project requirements includes customized mounting structures that also come with proper certification (ISO, CE, TUV etc.).


Photovoltaic mounting systems (also called solar module racking) are used to fix solar panels on surfaces like roofs, building facades, or the ground.These mounting systems generally enable retrofitting of solar panels on roofs or as part of the structure of the building called building integrated photovoltaic s (BIPV).

Types of Mounting Systems
1.Flush to Roof Racking System or InRoof System:

A flush photovoltaic system requires the panels to be fitted flush to the roof of your property making it one of the most popular ways of fitting PV solar panels because it will provide the most solar power and once installed, it looks better than means of installation. In roof systems look as if they fit seamlessly to the roof as they require a portion of the roof tiles to be removed allowing the solar panels to be fitted to the roof in their place. As well as having the panels fitted it is necessary to also have an inverter which will convert the power from DC into AC power that can be used in the house.

Flush mount roof racks keep the modules down on the roof, just a few inches above the roofing material. This is the least obtrusive visually, and therefore is popular in suburbs and higher-density residential areas. The major drawback of this mounting system is that the solar array has to face whichever direction the roof faces (which is usually not due south) and has to lie at the angle of the roof's pitch (which is usually not the optimal angle). What this means in real terms is that you don't get as much power out of your solar panels as you could. They also tend to create higher temperatures for the panels, which also slightly lowers their output. For this type of installation we use Unirac SolarMount racks.


The PV panels sit flush with the surrounding roof tiles using a special mounting system which removes the tiles underneath the PV panels.  This can be a more attractive option but is also slightly more expensive than the standard on-roof system.

Solar Roof Mounts are used to install solar panels on an inclined or flat roof. These mounting structures are usually made of aluminum or stainless steel.

What are Solar Roof Mounts?
Solar Roof Mounts, as the name suggests, is a mechanism with which the PV Panels can be installed upon the roof.


In an area which is populated with short trees or buildings, this may be the best possible installation. This could be achieved either by running aluminum or stainless steel rails along the roof and then attaching the panels to those rails, or by placing multiple brackets on the roof top, at certain distances, and attaching the panels to those brackets.

Disadvantage Solar Roof Mounts
Roof penetration
One disadvantage of using Roof Mount structures is that it requires penetration through the roof which may result in leaks and dampness.

Roof mounted structures typically keep the wire run distances between the solar array and the battery bank or inverter to a minimum, but require roof penetrations and run danger of causing roof leakages, thus the roof must be well sealed.

Roof loading capacity
Also, there is only a certain number of panels which you could install upon the roof depending upon the loading capacity and structural strength of the roof.

Roof orientation
Another disadvantage of roof mounted structures can come up if the roof orientation and angle is not optimal, thus wasting lots of potential energy that your system could generate.

For optimal system efficiency using a roof mounted structure you need to ensure that there is no shadow from trees or other buildings in the “optimally free “ airflow path of your solar panels.


Moreover, according to 690-5 of the US National Electrical Code-NEC they require expensive ground fault protection (GFP).
source:  http://sinovoltaics.com/

2.Tilt Up Racking Sysem:

Fixed Tilt Solar Racking System is applicable to install the usual framed module to tilt a certain angle with the roof. The solar system can be a fixed angle or adjustable such as 10~15 deg, 15~30 deg and 30~60 deg for your requirement. The special extruded aluminum rail, the tilt-in module, the clamp kit and the round leg can be high pre-assembly and make the installation easy and quick to save your labor cost and time. The customized length can eliminate the weld and cut onsite to keep the high anticorrosive performance, the structure strength and the appearance.

Tilt-up racks can be angled up off a roof's pitch to the optimal angle for your area and can be seasonally adjusted. They are more visually obtrusive than flush mount racks, but in most instances they allow the panels to produce more energy. Tilt-up racks can also be turned to face due south on a roof that faces off south, again increasing energy production.

source:http://www.gracesolar.com/

3.Ballast Racking System:
Ballast mounts rely solely on the weight of the array, racking system and additional material, like concrete pavers, to hold the array to the roof. Their biggest advantage is the lack of roof penetrations. This does not eliminate the need for working with a roofing contractor, but it can significantly reduce the coordination required between the roofer and the PV installer. These arrays can generally be installed while maintaining the roof warranty. But in order to do so, the installation must be coordinated with the original roofer or an approved representative for the roofing manufacturer. Ballasted systems need to be carefully analyzed due to the increased roof loading imposed by the array. Also, many ballasted systems will be limited to a pitch of 20° or less to minimize wind uplift forces.

Solar panel arrays are well suited for placing on flat roofs of large buildings and the mounting of these panels can be performed a number of ways, roof penetrating and ballasted. Roof penetrating mounting systems are not desirable due to the high labor costs and voiding the manufacturer's warranty. Ballasted mounting systems are held on the roof using weights, are simple to install and do not void the roof warranty.
Occasionally, solar panels are placed in a yard or field which are mounted on either a pole or upon ground-mounted racks. Although these types of systems have additional associated costs, it is sometimes the best option if the roof in question does not have good orientation, does not have adequate sun exposure, or is structurally unsuitable for holding the solar array. Ground-mounted PV systems typically include extra costs for concrete pads, digging trenches, additional conduit, wire, design costs, and additional permitting or zoning costs.
4.Top of the pole Racking system:

Top-of-pole mounts are structures where mounting poles are secured into the ground and tightened with concrete and the solar module is mounted on the top of the poles.

Advantages Top-of-Pole Mounts

The advantage is that it is rather not exposed to vandalism and accumulation of dirt, leaves and snow. These types of mounting structures can hold between 1 and 20 solar panels per pole.

The inclination of the mount can usually be adjusted manually according to the seasons. Some top-of-pole mounts have a tracker included.

Disadvantages Top-of-pole Mounts

Cleaning can be an issue as the panels are mounted way above ground. Maintenance crew needs special equipment to reach and clean the panels.

Winload capability Top-of-pole mounts
Similar to the Side-of-pole mounts,  you will need to take into account the windload capabilities of the pole and top-of-pole mount that you’re installing.

Most mounts are made to withstand winds up to 150km/u. However in many high-wind areas such as the coast, winload capability of 200km/u is recommended.

Row Spacing:
When designing a PV system that is tilted or ground mounted, determining the appropriate spacing between each row can be troublesome or a down right migraine in the making.  However, it is important to do it right the first time to avoid accidental shading from the modules that are ahead of each row.

Rule of thumb 3.5 times the height for row spacing.

in the American Technical Publishers’ textbook, Photovoltaic Systems. The formula given there for calculating minimum inter-row shading is:

                                                              d = h ÷ tan α

Where, d is the minimum distance between rows; h is the height differential between the top of one row and the bottom of the row to the north; and α is the solar altitude angle.


Data Sheets:
http://www.sflex.com/htdocs/phocadownload/sflex_td_pr_usa.pdf
http://www.nepcindia.co.in/images/NEPC-MMS.pdf